System and method for filling and dispensing orders

ABSTRACT

A method of filling prescription orders includes inputting the prescription orders into a pharmaceutical storage and retrieval device, processing the prescription orders with the pharmaceutical storage and retrieval device to fill a plurality of vials with desired pharmaceuticals, and transferring the plurality of filled vials from the pharmaceutical storage and retrieval device to a storage unit. The method also includes storing the plurality of filled vials in the storage unit until a customer claims one of the plurality of filled vials and directing the one of the plurality of filled vials from the storage unit to the customer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/708,935, filed Oct. 2, 2012, the entire contents of which areincorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to systems and methods for filling anddispensing orders. More particularly, the present invention relates tosystems and methods for filling and dispensing prescription orders tocustomers in retail pharmacy settings.

SUMMARY

In one embodiment, the invention provides a method of fillingprescription orders. The method includes inputting the prescriptionorders into a pharmaceutical storage and retrieval device, processingthe prescription orders with the pharmaceutical storage and retrievaldevice to fill a plurality of vials with desired pharmaceuticals, andtransferring the plurality of filled vials from the pharmaceuticalstorage and retrieval device to a storage unit. The method also includesstoring the plurality of filled vials in the storage unit until acustomer claims one of the plurality of filled vials and directing theone of the plurality of filled vials from the storage unit to thecustomer.

In another embodiment, the invention provides a method of restockingunclaimed prescription orders. The method includes filling a vial withpharmaceuticals using a pharmaceutical storage and retrieval device,transferring the filled vial from the pharmaceutical storage andretrieval device to a storage unit, and storing the filled vial in thestorage unit until a customer claims the filled vial. The method alsoincludes monitoring a length of time that the filled vial is stored inthe storage unit and returning the filled vial to the pharmaceuticalstorage and retrieval device if the filled vial is unclaimed by thecustomer after a predetermined period of time.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a pharmacy including a system forfilling and dispensing orders that embodies the invention.

FIG. 2 is a rear perspective view of the pharmacy including the systemfor filling and dispensing orders.

FIG. 3 is a top plan view of the pharmacy including the system forfilling and dispensing orders.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

FIGS. 1-3 illustrate a system 10 for filling and dispensing prescriptiondrug or other pharmaceutical orders in a pharmacy. The illustratedsystem 10 includes a production area 14 for filling prescription orders,a will call area 18 for temporarily storing the filled prescriptions,and a sales area 22 for distributing the filled prescriptions tocustomers.

The production area 14, or room, is somewhat isolated and out of view ofcustomers to create a more productive factory-like environment forprocessing and filling orders. The production area 14 may alternativelybe visible to customers or managers within the pharmacy. The productionarea 14 includes a system 26 to fill prescription orders. In theillustrated embodiment, the system 26 includes two pharmaceuticalstorage and retrieval devices 28. The illustrated devices 28, or towers,are the pharmaceutical storage and retrieval devices disclosed in U.S.patent application Ser. No. 12/870,045, filed Aug. 27, 2010, the entirecontents of which are incorporated by reference herein. In otherembodiments, the system 26 can include fewer or more pharmaceuticalstorage and retrieval devices 28, depending on the volume or demand ofprescription orders in the pharmacy.

The devices 28 receive and process prescription orders to fill vials and“unit of use” packs with the desired pharmaceuticals (e.g., drugs,narcotics, equipment, etc.). A control system including a processor,memory, and an input device is coupled to the devices 28. The inputdevice allows a user (e.g., a pharmacist or other technician) to input aseries of prescription orders into the control system. The devices 28then process the prescription orders to fill vials or other containersthrough a partially automated process for particular patients orcustomers. As discussed in U.S. patent application Ser. No. 12/870,045,each device 28 includes a gantry assembly that moves the pharmaceuticalswithin the device 28 for access by the user. Operation (e.g., movement)of the gantry assembly is controlled by the control system based on theinputted prescription orders.

After the vials and unit of use packs are filled, the filled vials andpacks can be transferred directly to a pharmacist for sale to a customeror can be transferred to the will call area 18 for temporary storageuntil a customer arrives. For example, filled vials and packs aretransferred to the will call area 18 when a customer is coming for nextday pickup or at a later time. Conveyors 30 are positioned adjacent thedevices 26 to hold the filled vials and packs until the vials and packscan be taken to the will call area 18 or the sales area 22. In someembodiments, the conveyors 30 may be automated and configured toautomatically transfer the filled vials and packs to the will call area18 and/or the sales area 22.

Existing will call systems process prescriptions under the assumptionthat the prescriptions are sold. That is, the existing systems removethe filled prescriptions from on-hand inventory and decrease a refillcounter accordingly, no matter how long the filled prescription sits inwill call. However, as much as 20% of filled will call orders are neverclaimed and must be returned to stock. In most states, unclaimedprescriptions typically must be reversed and insurance money must berefunded within ten days. Pharmacies, however, normally wait fourteendays before reversing transactions since it is very time consuming to gothrough and locate unclaimed prescription vials. Furthermore, pharmaciesoften may claim to be out of a particular drug, yet still have doses ofthe drug sitting unclaimed in will call.

In contrast to existing will call systems, the system 10 illustrated inFIGS. 1-3 places filled prescription vials and packs in a sales pendingstate. In this state, the total inventory of a particular pharmaceutical(regardless of whether that pharmaceutical is part of a filledprescription) remains visible in the system 10 until a customer actuallycomes to claim and pick up the filled prescription. Unclaimedpharmaceuticals can thereby be used to fill other prescriptions that areclaimed beforehand.

The illustrated will call area 18 includes a storage tower or unit 34for receiving and storing filled vials from the pharmaceutical storageand retrieval devices 28 in the production area 14. Overall, the storageunit 34 is similar to each of the devices 28, but is a simplified orstripped-down version of one of the devices 28 because the storage unit34 does not need a user interface or inlet and outlet ports. The storageunit 34 is a high-density storage unit that is configured to hold andstore over 1000 filled prescription vials at a time. In someembodiments, the storage unit 34 may be about ten feet long and may holdmore than 6000 filled vials. In other embodiments, the size of thestorage unit 34 may vary to hold fewer or more filled vials, dependingon the need of the pharmacy.

As shown in FIG. 2, the storage unit 34 includes a storage space 35 anda gantry assembly 36. The storage space 35 is configured to receive andstore the filled vials of pharmaceuticals. Shelves or other suitablestructures may be positioned within the storage space 35 to facilitatestoring the filled vials in an orderly manner. The gantry assembly 36 ismovable within the storage space 35 to position and retrieve the vials.Similar to the gantry assembly disclosed in U.S. patent application Ser.No. 12/870,045, the illustrated gantry assembly 36 includes a gripperassembly 37 that can grasp the vials and is operated by a control systemhaving a processor and memory.

Referring to FIG. 3, the illustrated storage unit 34 also includes afeeder 39 to help load filled vials into the unit 34. The feeder 39allows a user to position a group of filled vials on the storage unit 34without having to manually load the vials into particular locationswithin the storage space 35. Instead, the filled vials can be placed onthe feeder 39 by the user, and the gantry assembly 36 can load the vialsfrom the feeder 39 into the storage space 35. Such an arrangement allowsthe user to rapidly feed filled vials into the storage unit 34 withouthaving to check and confirm the proper location for each vial with thestorage space 35. As the gantry assembly 36 loads the vials into thestorage space 35, the control system (which may be integrated with thecontrol system of the devices 28) tracks the location of each of thevials in the storage unit 34. In the illustrated embodiment, the feeder39 includes a horizontal shelf with a series of cubby holes, or ports,for temporarily receiving the vials. In other embodiments, the feeder 39may include a vertical dispenser column or other suitable structure thatreceives the vials until the vials are loaded into the storage space 35by the gantry assembly 36.

The storage unit 34 also includes an automatic scanner 40 (e.g., a barcode scanner, a RF scanner, etc.) and a scale 41. The scanner 40identifies the vials as the vials move into and/or out of the unit 34.The scanner 40 thereby helps track the location of each vial within thestorage space 35 as the gantry assembly 36 moves the vials. The scale 41weighs the vials as the vials are loaded into the storage unit 34 toverify that the vial was properly filled. For example, the scanner 40scans the vial to determine the type and amount of pharmaceuticals thatare expected to be in the vial, and the scale 41 weighs the vial todetermine the weight of the vial. The control system then compares theweight of the vial to an expected weight (based on information stored ina database) to determine whether the vial was properly filled. Ifproperly filled, the vial is loaded into and stored in the storage unit,and the location of the vial is saved in memory. If improperly filled, anotification (e.g., a text message, email alert, alarm, audible message,displayed message, etc.) is delivered to the user. The user can thenrefill the vial properly and load the refilled vial onto the feeder 40.In some embodiments, the scanner 40 and the scale 41 can be integratedinto the gripper assembly 37 of the gantry assembly 36 such that thescanning and weighing functions occur as the gantry assembly 26 movesand loads the vials. In other embodiments, such as the illustratedembodiment, the scanner 40 and the scale 41 may be located on the feeder40.

The illustrated will call area 18 also includes a secondary storagemachine 38 for receiving and storing containers that have differentsizes and shapes than the vials. In particular, the containers areshaped and sized such that they are incompatible with (i.e., too large,bulky, or cumbersome for) the storage unit 34. The containers are filled“unit of use” packs such as, for example, inhalers, syringes, bandages,and other devices not suitable for storage in a prescription vial. Thesecondary storage machine 38 may include a rotating rubber belt withvanes to divide and move the filled packs to an exit port. An inlet port43 in a top surface of the storage machine 38 allows a user to insertcontainers into the machine 38 between the vanes. In some embodiments,removable patient labels may be applied to the filled packs before thepacks are placed in the secondary storage machine 38 to help identifythe packs. Additionally or alternatively, the storage machine 38 may berefrigerated for storing certain types pharmaceuticals, such as insulin.

When a customer arrives to pick up his or her prescription, the filledprescription vials can be dispensed from the storage unit 34 throughtubes 42 or other suitable conduits. The tubes 42 extend from an outletof the storage unit 34 generally toward the sales area 22. The tubes 42are configured to receive one or more vials from the gantry assembly 36to direct the vials toward the customer. In the illustrated embodiment,each tube 42 includes a sensor 44 (e.g., an infrared or laser beam) thatdetects movement of the vials through the tube 42. The sensors 44 verifythat a vial actually was dispensed out of the storage unit 34.

Similarly, the filled containers may be dispensed from the secondarystorage machine 38 through tubes 46 or other suitable conduits. Thetubes 46 extend from the exit port of the machine 38 generally towardthe sales area 22. As the belt within the machine 38 rotates, a plungeror other suitable mechanism within the machine 38 pushes the containersthrough the exit port and into the tubes 46. In the illustratedembodiment, each tube 46 includes a sensor 48 (e.g., an infrared orlaser beam) that detects movement of the containers through the tube 46.The sensors 48 verify that a container actually was dispensed out of thesecondary storage machine 38.

The sales area 22 receives the filled vials and containers from the willcall area 18. The illustrated sales area 22 includes two automatedkiosks 50 and a counter 54. Depending on where a customer goes to pickup his or her prescription, the storage unit 34 and the secondarystorage machine 38 may dispense the filled prescription to either one ofthe kiosks 50 or a pharmacist working at the counter 54.

The kiosks 50 include touch screens, signature capture systems, andcredit/debit payment systems. In some embodiments, the kiosks 50 mayrequire a customer to login using a username and/or password in order touse and operate the kiosks 50. The kiosks 50 also include a slidablebank drawer-type device and a printer. The drawer-type device receivesthe filled prescription from the tubes 42, 46 and releases theprescription to a customer once identification and payment are approved.The printer prints associated paperwork for the prescription, such asinstructions for use and receipts. In some embodiments, the printer maynot print the paperwork until requested by the customer. Such anarrangement reduces paper waste if the customer is already familiar withthe prescription. Each kiosk 50 can also include a camera to monitor thecustomer as the customer interacts with the kiosk 50. Unlike the counter54, the kiosks 50 allow a customer to pick up his or her prescriptionafter hours when a pharmacist is no longer available.

Each kiosk 50 may also include a detector or sensor to detect that thecustomer actually takes the prescription and printed material from thekiosk 50. The kiosks 50 may also include a recovery feature to “pullback” filled vials and packs (as well as any associated printedmaterial) if a customer walks away without taking his or herprescription. For example, if the customer does not open the lid of thedrawer-type device within a certain period of time (e.g., one minute),the kiosk 50 can automatically slide back behind a wall of the pharmacyand drop the unclaimed prescription into a collection bin. This featurecan help protect confidential patient healthcare information.

The filled vials and packs from the will call area 18 can alternativelybe dropped into catch bins 58 behind a wall of the pharmacy. The bins 58are accessible directly by the pharmacy staff. The bins 58 allow thevials and packs to be delivered to customers from a pharmacist, or otherstaff member, working at the counter 54 rather than through the kiosks50.

The storage unit 34 and the secondary storage machine 38 allow storageof filled vials and packs without printing drug information and/orpatient-specific information on, for example, a monograph. Such anarrangement reduces the amount of storage space needed for themonographs. Instead, the monograph can be printed when the customerarrives to pick up the vial or pack at one of the kiosks 50 or at thecounter 54. A customer can also choose not to have this informationprinted if the customer is already familiar with the prescription,reducing excess paper waste.

The storage unit 34 and the secondary storage machine 38 can alsoautomatically return filled vials and containers to the pharmaceuticalstorage and retrieval devices 28 if the vials or containers areunclaimed by a customer after a predetermined period of time. Once aprescription order is filled, the filled vials or containers are loadedinto the storage unit 34 or the storage machine 38, as described above.The control system monitors a length of time that the vials andcontainers are stored in the unit 34 or the machine 38. Alternatively,the control system can monitor a length of time from when theprescriptions are filled. If the filled vials and containers areunclaimed after, for example, ten days, the storage unit 34 and thesecondary storage machine 38 direct the unclaimed vials and containersto a tote or bin (e.g., one of the bins 58) behind a wall of thepharmacy for restocking in the devices 28. The gantry assembly 36 in thestorage unit 34 and the plunger in the secondary storage machine 38 areoperated by the control system to direct the unclaimed vials andcontainers into a suitable bin using one of the corresponding conduits42, 46. This automatic unloading may occur overnight while the pharmacyis closed and not in operation.

In the morning, pharmacy staff collects the unclaimed vials andcontainers from the bin. The staff then transfers the vials andcontainers back to the pharmaceutical storage and retrieval devices 28in the production area 14 by inserting the filled vials and containersinto inlet ports in the devices 28. The unclaimed, filled vials andcontainers are thereby placed back into stock. The filled vials andcontainers are returned to the devices 28 without removing thepharmaceuticals stored inside the vials and containers. In somescenarios, patient labels may also be left on the vials because thedevices 28 are enclosed and, thereby, prevent users or other personnelfrom reading or accessing the pharmaceuticals stored in the devices 28.That is, the labels do not need to be altered (e.g., blacked-out,removed, or otherwise obliterated) when the vials are returned to thedevices 28. In such scenarios, the vials may be re-dispensed if theappropriate customer ever arrives to claim the vials. Alternatively, thepatient labels may be removed once the vials are needed to fill aprescription order for a different customer.

The system 10 requires fewer technicians to fill orders, maintainsaccurate inventory in a secure manner, allows visibility of finished(e.g., filled) vial and pack inventory, and stores the finishedinventory securely. The system 10 thereby provides, among other things,higher security, accuracy in delivering the correct items to patients, asingle location for storage of all finished/filled goods, and a kioskdelivery system for self-checkout.

Various features and advantages of the invention are set forth in thefollowing claims.

The invention claimed is:
 1. A method of filling prescription orders,the method comprising: inputting the prescription orders into apharmaceutical storage and retrieval device; processing the prescriptionorders with the pharmaceutical storage and retrieval device to fill aplurality of vials with desired pharmaceuticals; transferring theplurality of filled vials from the pharmaceutical storage and retrievaldevice to a storage unit; storing the plurality of filled vials in thestorage unit until a customer claims one of the plurality of filledvials; and directing the one of the plurality of filled vials from thestorage unit to a store kiosk that is accessible to the customer,wherein a conduit extends from an outlet of the storage unit to thestore kiosk, and wherein directing the one of the plurality of filledvials includes directing the one of the plurality of filled vialsthrough the conduit from the storage unit to the store kiosk, whereintransferring the plurality of filled vials includes moving the pluralityof filled vials from the pharmaceutical storage and retrieval device toa feeder of the storage unit, and wherein the storage unit includes agantry assembly, and further comprising operating the gantry assembly tomove the plurality of filled vials from the feeder to a storage spaceinside the storage unit.
 2. The method of claim 1, further comprisingoperating the gantry assembly to retrieve the one of the plurality offilled vials from the storage space of the storage unit when thecustomer claims the one of the plurality of filled vials.
 3. The methodof claim 1, wherein the storage unit is a high-density storage unit, andwherein storing the plurality of filled vials includes simultaneouslystoring over one thousand filled vials in the storage unit.
 4. Themethod of claim 1, further comprising verifying, at the storage unit,that each of the plurality of filled vials is correctly filled.
 5. Themethod of claim 4, wherein the storage unit includes at least one of abar code scanner and a scale, and wherein verifying that each of theplurality of filled vials is correctly filled includes at least one ofscanning each of the plurality of filled vials with the bar code scannerand weighing each of the plurality of filled vials with the scale. 6.The method of claim 1, further comprising: storing a plurality of filledcontainers in a secondary storage machine until the customer claims oneof the plurality of filled containers, the plurality of filledcontainers having different sizes and shapes than the plurality offilled vials; and directing the one of the plurality of filledcontainers from the secondary storage machine to the customer.
 7. Themethod of claim 6, wherein directing the one of the plurality of filledvials includes directing the one of the plurality of filled vials fromthe storage unit through a first conduit to the customer, and whereindirecting the one of the plurality of containers includes directing theone of the plurality of containers from the secondary storage machinethrough a second conduit to the customer.
 8. The method of claim 6,further comprising refrigerating the plurality of containers storedwithin the secondary storage machine.
 9. A method of fillingprescription orders, the method comprising: inputting the prescriptionorders into a pharmaceutical storage and retrieval device; processingthe prescription orders with the pharmaceutical storage and retrievaldevice to fill a plurality of vials with desired pharmaceuticals;transferring the plurality of filled vials from the pharmaceuticalstorage and retrieval device to a storage unit; storing the plurality offilled vials in the storage unit until a customer claims one of theplurality of filled vials; directing the one of the plurality of filledvials from the storage unit to a store kiosk that is accessible to thecustomer; wherein a conduit extends from an outlet of the storage unitto the store kiosk, and wherein directing the one of the plurality offilled vials includes directing the one of the plurality of filled vialsthrough the conduit from the storage unit to the store kiosk; anddetecting, by a sensor coupled to the conduit, movement of the one ofthe plurality of filled vials through the conduit.
 10. A method ofrestocking unclaimed prescription orders, the method comprising: fillinga vial with pharmaceuticals using a pharmaceutical storage and retrievaldevice; transferring the filled vial from the pharmaceutical storage andretrieval device to a storage space of a storage unit; storing thefilled vial in the storage unit until a customer claims the filled vial;monitoring a length of time that the filled vial is stored in thestorage unit; directing the filled vial out of the storage space andinto a bin of the storage unit when the filled vial is unclaimed by thecustomer after a predetermined period of time; and returning the filledvial from the bin to the pharmaceutical storage and retrieval device.11. The method of claim 10, wherein returning the filled vial includesreturning the filled vial to the pharmaceutical storage and retrievaldevice if the filled vial is unclaimed by the customer after ten days.12. The method of claim 10, wherein returning the filled vial to thepharmaceutical storage and retrieval device includes collecting thefilled vial from the bin and inserting the filled vial into thepharmaceutical storage and retrieval device.
 13. The method of claim 10,wherein the storage unit includes a gantry assembly, and furthercomprising operating the gantry assembly to move the filled vial fromthe storage unit to the bin.
 14. The method of claim 10, furthercomprising storing the returned vial within the pharmaceutical storageand retrieval device without removing the pharmaceuticals from thereturned vial.
 15. The method of claim 14, wherein storing the returnedvial includes storing the returned vial within the pharmaceuticalstorage and retrieval device without altering a label on the returnedvial.